Co2 generator and dehydrator

ABSTRACT

Disclosed herein is an apparatus for improving plant growing conditions, the apparatus in one form comprising: a housing; a carbon dioxide (CO2) producing section; and an exhaust section. The CO2 producing section in form comprises: an inlet through the housing for ambient air, an inlet through the housing for fuel gas, a burner for oxidizing the fuel gas; an oxidized gas outlet flue, and a dehydrator for removing the water vapor from the oxidized gas produced in the CO2 producing section. The dehydrator section may in turn comprise: a cooling water inlet through the housing; a plurality of heat exchangers in fluid communication with the cooling water inlet and in fluid communication with the oxidized gas outlet flue; and at least one condensate trap in fluid communication with a condensate outlet. The dehydrator section may comprise a cooling water outlet through the housing in fluid communication with the heat exchangers.

RELATED APPLICATIONS

This application claims priority benefit of U.S. Ser. No. 61/411,571 filed on Nov. 9, 2010 incorporated herein by reference.

BACKGROUND OF THE DISCLOSURE a) Field of the Disclosure

This disclosure relates to the field of a carbon dioxide generator with water vapor removal system (dehydrator). One significant use of such a device is in greenhouse use or elsewhere where plants are grown.

SUMMARY OF THE DISCLOSURE

Disclosed herein is an apparatus for improving plant growing conditions, the apparatus in one form comprising: a housing; a carbon dioxide (CO2) producing section; and an exhaust section. The CO2 producing section in form comprises: an inlet through the housing for ambient air, an inlet through the housing for fuel gas, a burner for oxidizing the fuel gas; an oxidized gas outlet flue, and a dehydrator for removing the water vapor from the oxidized gas produced in the CO2 producing section. The dehydrator section may in turn comprise: a cooling water inlet through the housing; a plurality of heat exchangers in fluid communication with the cooling water inlet and in fluid communication with the oxidized gas outlet flue; and at least one condensate trap in fluid communication with a condensate outlet through the housing. The dehydrator section may also comprise a cooling water outlet through the housing in fluid communication with the heat exchangers. The apparatus in one form comprising: an exhaust section downstream of the heat exchangers, the exhaust section comprising a flue gas exhaust releasing the oxidized fuel/air mixture into the atmosphere.

In one embodiment, the condensate trap comprises: a water collecting and diverting trough; a fluid drain in the lowermost portion of the trough; a plurality of angled wings positioned above and outward of the trough; and the angled wings may be angled so as to direct rising oxidized gas away from the center of the trough and direct water dripping thereupon into the trough.

In one form the apparatus as recited in claim 1 wherein the cooling water enters the uppermost heat exchanger and then enters lower heat exchangers in series.

The apparatus as described may further comprise; sensors to monitor the temperature and/or water vapor content of the oxidized fuel/air mixture in the exhaust section; and control devices which adjust the flow rate of the cooling water flow rate and/or fuel gas flow rate in relation to the temperature and/or water vapor content of the oxidized fuel/air mixture in the exhaust section.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front isometric view of one embodiment of a carbon dioxide generator and dehydrator.

FIG. 2 is a front isometric view of the embodiment of FIG. 1 with the outer casing removed to show the internal components.

FIG. 3 is a rear isometric view of the embodiment of FIG. 1 with the outer casing removed to show the internal components.

FIG. 4 is a rear isometric detail view of the burner portion of the embodiment shown in FIG. 1.

FIG. 5 is a front isometric detail view of the embodiment shown in FIG. 4.

FIG. 6 is an isometric view of one embodiment of a condensate trap.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Looking to FIG. 1, the CO2 generator and dehydrator 20 is shown with the housing 34 shown substantially transparent so as to allow a relational view of the housing 34 to the internal components. Generally, in a production model, the housing 34 would not be transparent or translucent, as most end-users would not desire to see the internal components during operation. By way of description, the housing 34 in one form comprises a front housing 22 and a rear housing 24, although other arrangements could be utilized. By way of orientation, the apparatus 20 comprises a right side 26, left side 28, front side 30 and back side 32. In one form, the housing 34 includes a right vent 36 and left vent 38, which are generally openings from ambient air to the internal components to allow passage of ambient air for reasons that will be described herein. To further aid in describing the apparatus 20, an axes system 10 is utilized, comprising a vertical axis 12 and a transverse axis 14, which is perpendicular to the vertical axis 12 and parallel to the left side 28. A lateral axis 16 is also described as being perpendicular both to the vertical axis 12 and the transverse axis 14. This axes system 10 is not intended to be limiting, but is utilized herein to further aid in describing the relationship between individual components.

In addition to the vents 36 and 38, the housing 34 may comprise a fan opening 40, generally in line with a flue gas exhaust fan 42. Additionally, an opening for a carbon dioxide temperature indicator 44 may be provided. The carbon dioxide temperature indicator 44, in one form, displays the temperature of the exhausting gases, and may also display the water content/humidity, CO2 level, etc., which may be of great assistance to the user. Additionally, openings may be provided for a water inlet temperature indicator 46 and a water outlet temperature indicator 48. In general, the apparatus 20 accepts water through a water inlet 50, and the temperature of the water entering the water inlet 50 may be indicated at the water inlet temperature indicator. Additionally, the apparatus comprises a water outlet 52, and it may be desired to have the indicator 48 display the water outlet temperature.

Looking now to FIG. 2, one form of the apparatus 20 is shown comprising several interoperating components. A control section 54 is shown at the lowermost portion and generally comprises conduits for the passing of fuel gas, ambient air, and water. Above the control section 54 is a burner section 56, which generally comprises a fuel burner 58 and is connected to the control section 54. Above the burner section 56 is a dehydrator section 60, generally comprising a plurality of heat exchangers 62, 64 and 66. Additionally, the dehydrator section 60 in one form comprises a condensate trap 68, which is connected by way of piping 70 to a condensate outlet 72. Above the dehydrator section 60 is an uppermost exhaust section 74, which comprises the flue gas exhaust 42, as shown in FIG. 1.

In operation, in one form, when the apparatus 20 is energized or turned on, gas enters the gas inlet 76 and passes to the adjustment valve 78, which is attached to a control knob 81. If the valve 78 is opened, the flow of gas will increase through the valve 78 to the fuel burner 58, at which point it may be ignited, such as by a piezzo electric igniter 80 or equivalent device, commonly known in the art. In one form, the valve 78 is not a shutoff style valve, but is a valve operatively selected and configured to limit the burner to a temperature range of 12K-36K BTU. The burning of the fuel creates a convection draft upward as the heated air rises from the burner 58, through a flue 82 and towards the first heat exchanger 62. In one form, rising of the heated air creates a partial vacuum in the control section 54, which is filled as ambient air enters through the vents 36 and 38 of the housing 34. Inlet fans may also be utilized. As the exhaust gas rises through the flue 82 into the first heat exchanger 62, some of the heat is absorbed by the fins 84 of the heat exchanger 62. These fins 84 are connected to piping 86 (through which cooling water flows) and thus, through thermal convection, the heat is transferred from the exhaust gas to the fins 84 to the cooling water within the piping 86, whereupon it is drained by way of the water outlet 52. At this point, the flue gas will have been cooled very little and convection will still draw the flue gases upward through the condensate trap 68.

Looking to FIG. 6, the condensate trap 68 in one form generally consists of a trough 88 comprising a plurality of sidewalls 90 and 92, end walls 94 and 96, and a base 98. The rising flue gases pass around the base 98 and sidewalls 90 and 92, through the gaps 100 and 102 between the trough 88 and the outer housing 34, which is not shown in FIG. 6. The condensate trap 68 further comprises a drain 104, which connects to the condensate outlet drain 72. It can be seen how the rising flue gases rise through the heat exchanger 62, past the sidewalls 90 and 92, and are directed outward by way of the angled wings 106 and 108 away from center of the condensate trap 68. As previously mentioned, the flue gases are considerably warmer than the ambient air entering the lower portion of the apparatus 20 and, therefore, continue to rise due to convection. The flue gases then pass through heat exchangers 64 and 66, which operate in the same manner as the heat exchanger 62.

The apparatus, in one form, is arranged such that the cooling water enters via the inlet 50 and goes first to the upper heat exchanger 66, which will be the coolest of the heat exchangers. Once the cooling water passes through the heat exchanger 66 and a significant portion of the heat is removed from the flue (oxidized) gases, the cooling water then enters the heat exchanger 64, travels downward toward the heat exchanger 62, and then exits by way of the water outlet 52. As the flue gases cool, water condenses upon the fins and tubes of the heat exchangers 64 and 66. This condensed water tends downward due to gravity toward the condensate trap 68, whereupon it drips upon the base 98 and wings 106/108. As the wings 106/108 are angled inward, and wherein the inner edges 110 and 112 are transversely inward from the sidewalls 90 and 92, the water will drip from the wings into the trough 88, whereupon it will be directed toward the drain 104 and out through the condensate drain 72, whereupon it may be collected and recycled.

Looking now to FIG. 3, it can be seen how in this embodiment the exhaust section 74 sits above the uppermost heat exchanger 66. As the flue gases, at this point, may be substantially the same temperature as or potentially cooler than ambient air, convection will not exhaust the cooled air or flue gases upward and may tend to force the cooled gases downward back through the apparatus, which is undesired. Therefore, an exhaust fan 42 is provided in the exhaust section 74. Additionally, sensors and an indicator 44 (which may include an outlet air temperature indicator) may be provided, such that a user can configure the apparatus to provide exhaust gases at the proper temperature, water content, and/or carbon dioxide level. The exhaust section 74 may alternatively be positioned to a side of the heat exchanger 66.

Looking to FIG. 5, the control section 54 is shown quite clearly. This portion is also shown quite clearly from the opposite angle in FIG. 4. When the apparatus is turned off, the fuel flow control knob 81 may be positioned so as to close the adjustment valve 78 such that fuel gas will not flow through the system. In one form, the apparatus 20 comprises failsafe devices, such as an automatic shutoff, should water flow, gas flow, or gas pressure drop below a certain level. In one form, an inlet pressure gauge 114 is provided, which may be connected to display the inlet pressure of the fuel and/or to shut off the gas pressure when the gas pressure drops below a certain level for safety reasons.

Additionally, a water flow control knob 116 is disclosed connected to a water flow control valve 118, which controls the volume of water between the water inlet 50 and conduits 120 leading toward the heat exchangers previously described. Additionally, pressure sensors, flow sensors, and/or temperature sensors may be included in the water supply line, which are then displayed, in one form, in the water inlet temperature indicator 46. For safety reasons, a water/gas interconnect valve 122 may be provided, which stops the flow of gas to the burner portion 58 when the water pressure drops below a certain level, again for safety reasons.

Additionally, it is obvious that when the flow of gas to the burner 58 is shut off that the flame in the burner 58 will go out. Thus, it may be desired to have a relight circuit connected to the pressure gauge 114, such that when the pressure again rises to an adequate level at the fuel inlet 76, actuated valves would re-open between the inlet 76 and the burner 58 and the piezzo igniter 80 will reinitialize to relight the apparatus without requiring a manual reset.

While the present invention is illustrated by description of several embodiments and while the illustrative embodiments are described in detail, it is not the intention of the applicants to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications within the scope of the appended claims will readily appear to those sufficed in the art. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus and methods, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of applicants' general concept. 

1. An apparatus for improving plant growing conditions, the apparatus comprising: a. a housing; b. a carbon dioxide (CO2) producing section which in turn comprises: i. an inlet through the housing for ambient air, ii. an inlet through the housing for fuel gas, iii. a burner for oxidizing the fuel gas, iv. an oxidized gas outlet flue, c. a dehydrator for removing the water vapor from the oxidized gas produced in the CO2 producing section, the dehydrator section comprising: i. a cooling water inlet through the housing; ii. a plurality of heat exchangers in fluid communication with the cooling water inlet and in fluid communication with the oxidized gas outlet flue; iii. at least one condensate trap in fluid communication with a condensate outlet through the housing; iv. a cooling water outlet through the housing in fluid communication with the heat exchangers; d. an exhaust section downstream of the heat exchangers, the exhaust section comprising a flue gas exhaust releasing the oxidized fuel/air mixture into the atmosphere.
 2. The apparatus as recited in claim 1 wherein the condensate trap comprises: a. a water collecting and diverting trough; b. a fluid drain in the lowermost portion of the trough; c. a plurality of angled wings positioned above and outward of the trough; and d. the angled wings are angled so as to direct rising oxidized gas away from the center of the trough and direct water dripping thereupon into the trough.
 3. The apparatus as recited in claim 1 wherein the cooling water enters the uppermost heat exchanger and then enters lower heat exchangers in series.
 4. The apparatus as recited in claim 1 further comprising; a. sensors to monitor the temperature and/or water vapor content of the oxidized fuel/air mixture in the exhaust section; and b. control devices which adjust the flow rate of the cooling water flow rate and/or fuel gas flow rate in relation to the temperature and/or water vapor content of the oxidized fuel/air mixture in the exhaust section. 